Ch03 SPC and Process Capability

Chapter 3
Process Capability and

Statistical Process Control
Lecture Outline
Basics of Statistical Process Control

Control Charts
Control Charts for Attributes
Control Charts for Variables
Control Chart Patterns
SPC with Excel and OM Tools
Process Capability
Copyright 2011 John Wiley & Sons, Inc.
3-2
Statistical Process Control (SPC)

Statistical Process Control
monitoring production process
to detect and prevent poor
quality
Sample
subset of items produced to
use for inspection
Control Charts
process is within statistical
control limits
3-3
Process Variability
Random
inherent in a process
depends on equipment
and machinery,
engineering, operator,
and system of
measurement
natural occurrences
Non-Random
special causes
identifiable and
correctable
include equipment out of
adjustment, defective
materials, changes in
parts or materials, broken
machinery or equipment,
operator fatigue or poor
work methods, or errors
due to lack of training
3-4
SPC in Quality Management

SPC uses
Is the process in control?
Identify problems in order to make
improvements
Contribute to the TQM goal of continuous
improvement
3-5
Quality Measures:
Attributes and Variables
Attribute
A characteristic which is evaluated with a
discrete response
good/bad; yes/no; correct/incorrect
Variable measure
A characteristic that is continuous and can be
measured
Weight, length, voltage, volume
3-6
SPC Applied to Services

Nature of defects is different in services
Service defect is a failure to meet customer
requirements
Monitor time and customer satisfaction
3-7

Hospitals
timeliness & quickness of care, staff responses to requests,
accuracy of lab tests, cleanliness, courtesy, accuracy of
paperwork, speed of admittance & checkouts
Grocery stores
waiting time to check out, frequency of out-of-stock items, quality
of food items, cleanliness, customer complaints, checkout
register errors
Airlines
flight delays, lost luggage & luggage handling, waiting time at
ticket counters & check-in, agent & flight attendant courtesy,
accurate flight information, cabin cleanliness & maintenance
3-8

Fast-food restaurants
waiting time for service, customer complaints, cleanliness, food
quality, order accuracy, employee courtesy
Catalogue-order companies
order accuracy, operator knowledge & courtesy, packaging,
delivery time, phone order waiting time
Insurance companies
billing accuracy, timeliness of claims processing, agent
availability & response time
3-9
Where to Use Control Charts

Process
Has a tendency to go out of control
Is particularly harmful and costly if it goes out of control
Examples
At beginning of process because of waste to begin
production process with bad supplies
Before a costly or irreversible point, after which product is
difficult to rework or correct
Before and after assembly or painting operations that
might cover defects
Before the outgoing final product or service is delivered
3-10
Control Charts
A graph that monitors process quality
Control limits
upper and lower bands of a control chart
Attributes chart
p-chart
c-chart
Variables chart
mean (x bar chart)
range (R-chart)
3-11
Process Control Chart

Out of control
Upper
control
limit
Process
average
Lower
control
limit
10
Sample number
3-12
Normal Distribution
Probabilities for Z= 2.00 and Z = 3.00
95%
99.74%
-3
-2
-1
=0
3-13
A Process Is in Control If
1. no sample points outside limits
2. most points near process average
3. about equal number of points above
and below centerline
4. points appear randomly distributed
3-14
Control Charts for Attributes

p-chart
uses portion defective in a sample
c-chart
uses number of defects (non-conformities) in a
sample
3-15
p-Chart
UCL = p + zp
LCL = p - zp
z
p
p
=
number of standard deviations from process
average
=
sample proportion defective; estimates
process mean
= standard deviation of
proportion
p(1sample
- p)
p =
3-16
Construction of p-Chart
SAMPLE #
1
2
3
:
:
20
NUMBER OF
DEFECTIVES
PROPORTION
DEFECTIVE
6
0
4
:
:
18
200
.06
.00
.04
:
:
.18
20 samples of 100 pairs of jeans
3-17
p=
total defectives
total sample observations
UCL = p + z
= 200 / 20(100) = 0.10
p(1 - p)
= 0.10 + 3
n
0.10(1 - 0.10)
100
UCL = 0.190
LCL = p - z
p(1 - p)
= 0.10 - 3
n
0.10(1 - 0.10)
100
LCL = 0.010
3-18
0.20
UCL = 0.190
0.18
Proportion defective
0.16
0.14
0.12
0.10
p = 0.10
0.08
0.06
0.04
0.02
LCL = 0.010
2
8
10
12
Sample number
14
16
18
20
3-19
p-Chart in Excel
Click on Insert then Charts
to construct control chart
I4 + 3*SQRT(I4*(1-I4)/100)
I4 - 3*SQRT(I4*(1-I4)/100)
Column values copied

from I5 and I6
3-20
c-Chart
UCL = c + zc
LCL = c - zc
c =
where
c = number of defects per sample
3-21
c-Chart
Number of defects in 15 sample rooms
SAMPLE
NUMBER
OF
DEFECTS
1
2
3
12
8
16
:
:
:
:
15
15
190
190
c=
= 12.67
15
UCL = c + zc
= 12.67 + 3
= 23.35
12.67
LCL = c - zc
= 12.67 - 3
= 1.99
12.67
3-22
c-Chart
24
UCL = 23.35
Number of defects
21
18
c = 12.67
15
12
9
6
LCL = 1.99
10
12
14
16
Sample number
3-23
Control Charts for Variables

Range chart ( R-Chart )
Plot sample range (variability)
Mean chart ( x -Chart )

Plot sample averages
3-24
x-bar Chart: Known

UCL = x=+ z x=
LCL = x - z xWhere
=
X=
x- 1 + x- 2 + ... + x- k
k
= process standard deviation
x = standard deviation of sample means =/ n
k = number of samples (subgroups)
n = sample size (number of observations)
3-25
x-bar Chart Example: Known

Observations(Slip-Ring Diameter, cm) n
Sample k
x-
We know = .08
3-26
x-bar Chart Example: Known

= _____
50.09
X=
= 5.01
10
=
UCL = x + z -x
= 5.01 + 3(.08 / 10)
= 5.09
LCL = x=- z x= 5.01 - 3(.08 / 10)

= 4.93
3-27
x-bar Chart Example: Unknown

=
UCL = x + A2R
LCL = x - A2R
where
=
x = average of the sample means
_
R = average range value
3-28
Control
Chart
Factors
Sample
Size
n
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Factor for X-chart

A2
1.880
1.023
0.729
0.577
0.483
0.419
0.373
0.337
0.308
0.285
0.266
0.249
0.235
0.223
0.212
0.203
0.194
0.187
0.180
0.173
0.167
0.162
0.157
0.153
D3
0.000
0.000
0.000
0.000
0.000
0.076
0.136
0.184
0.223
0.256
0.283
0.307
0.328
0.347
0.363
0.378
0.391
0.404
0.415
0.425
0.435
0.443
0.452
0.459
Factors for R-chart

D4
3.267
2.575
2.282
2.114
2.004
1.924
1.864
1.816
1.777
1.744
1.717
1.693
1.672
1.653
1.637
1.622
1.609
1.596
1.585
1.575
1.565
1.557
1.548
1.541
3-29

OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k
1
2
3
4
5
6
7
8
9
10
5.02
5.01
4.99
5.03
4.95
4.97
5.05
5.09
5.14
5.01
5.01
5.03
5.00
4.91
4.92
5.06
5.01
5.10
5.10
4.98
4.94
5.07
4.93
5.01
5.03
5.06
5.10
5.00
4.99
5.08
4.99
4.95
4.92
4.98
5.05
4.96
4.96
4.99
5.08
5.07
4.96
4.96
4.99
4.89
5.01
5.03
4.99
5.08
5.09
4.99
4.98
5.00
4.97
4.96
4.99
5.01
5.02
5.05
5.08
5.03
0.08
0.12
0.08
0.14
0.13
0.10
0.14
0.11
0.15
0.10
Totals 50.09
1.15
3-30

_
R=
R
____
=
k
1.15
____
10 = 0.115
x
50.09
_____
=
___
x=
=
= 5.01 cm
10
k
_
=
UCL = x + A2R = 5.01 + (0.58)(0.115) = 5.08
=
LCL = x - A2R = 5.01 - (0.58)(0.115) = 4.94
3-31
x- bar
Chart
Example
5.10
5.08
UCL = 5.08
5.06
5.04
Mean
5.02
=
x = 5.01
5.00
4.98
4.96
4.94
LCL = 4.94
4.92
|
1
|
2
|
3
|
|
|
|
4
5
6
7
Sample number
|
8
|
9
|
10
3-32
R- Chart
UCL = D4R
R=
LCL = D3R
R
k
Where
R = range of each sample
k = number of samples (sub groups)
3-33
R-Chart Example
OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k
1
2
3
4
5
6
7
8
9
10
5.02
5.01
4.99
5.03
4.95
4.97
5.05
5.09
5.14
5.01
5.01
5.03
5.00
4.91
4.92
5.06
5.01
5.10
5.10
4.98
4.94
5.07
4.93
5.01
5.03
5.06
5.10
5.00
4.99
5.08
4.99
4.95
4.92
4.98
5.05
4.96
4.96
4.99
5.08
5.07
4.96
4.96
4.99
4.89
5.01
5.03
4.99
5.08
5.09
4.99
4.98
5.00
4.97
4.96
4.99
5.01
5.02
5.05
5.08
5.03
0.08
0.12
0.08
0.14
0.13
0.10
0.14
0.11
0.15
0.10
Totals 50.09
1.15
3-34
R-Chart Example
_
UCL = D4R = 2.11(0.115) = 0.243
_
LCL = D3R = 0(0.115) = 0
Retrieve chart factors D3 and D4
3-35
R-Chart Example
0.28
0.24
Range
0.20
0.16
0.12
UCL = 0.243
R = 0.115
0.08
0.04
0
LCL = 0
|
|
|
1
2
3
|
|
|
|
4
5
6
7
Sample number
|
8
|
9
|
10
3-36
X-bar and R charts Excel & OM Tools
3-37
Using x- bar and R-Charts

Together
Process average and process variability must be
in control
Samples can have very narrow ranges, but
sample averages might be beyond control limits
Or, sample averages may be in control, but
ranges might be out of control
An R-chart might show a distinct downward
trend, suggesting some nonrandom cause is
reducing variation
3-38

Run
sequence of sample values that display same
characteristic
Pattern test
determines if observations within limits of a control
chart display a nonrandom pattern
3-39

To identify a pattern look for:
8 consecutive points on one side of the center line

8 consecutive points up or down
14 points alternating up or down
2 out of 3 consecutive points in zone A (on one side of
center line)
4 out of 5 consecutive points in zone A or B (on one
side of center line)
3-40

UCL
UCL
LCL
LCL
Sample observations
consistently below the
center line
Sample observations
consistently above the
center line
3-41
3-41

UCL
UCL
LCL
LCL
Sample observations
consistently increasing
Sample observations
consistently decreasing
3-42
Zones for Pattern Tests

=
3 sigma = x + A2R
UCL
Zone A
=
2 sigma = x + 2 (A2R)
3
Zone B
=
1 sigma = x + 1 (A2R)
3
Zone C
Process
average
=
x
Zone C
=
1 sigma = x - 1 (A2R)
3
Zone B
=
2 sigma = x - 2 (A2R)
3
Zone A
=
3 sigma = x - A2R
LCL
|
1
|
2
|
3
|
4
|
5
|
6
|
7
|
8
|
9
|
10
|
11
|
12
|
13
Sample number
3-43
Performing a Pattern Test

SAMPLE
1
2
3
4
5
6
7
8
9
10
ABOVE/BELOW
UP/DOWN
ZONE
4.98
5.00
4.95
4.96
4.99
5.01
5.02
5.05
5.08
5.03
B
B
B
B
B
A
A
A
A
U
D
D
U
U
U
U
U
D
B
C
A
A
C
C
C
B
A
B
3-44
Sample Size Determination

Attribute charts require larger sample sizes
50 to 100 parts in a sample
Variable charts require smaller samples
2 to 10 parts in a sample
3-45
Process Capability
Compare natural variability to design variability
Natural variability
What we measure with control charts
Process mean = 8.80 oz, Std dev. = 0.12 oz
Tolerances
Design specifications reflecting product
requirements
Net weight = 9.0 oz 0.5 oz
Tolerances are 0.5 oz
3-46
Process Capability
3-47
Process Capability
3-48
Process Capability Ratio

Cp =
=
tolerance range
process range
upper spec limit - lower spec limit
3-49
Computing Cp
3-50
Process Capability Index
Cpk = minimum
=
x - lower specification limit
3
upper specification limit - =

x
3
3-51
Computing Cpk
Net weight specification = 9.0 oz 0.5 oz
Process mean = 8.80 oz
Process standard deviation = 0.12 oz
Cpk = minimum
=x - lower specification limit

,
3
upper specification limit - =
x
3
= minimum
8.80 - 8.50 9.50 - 8.80

,
= 0.83
3(0.12)
3(0.12)
3-52
Process Capability With Excel
=(D6-D7)/(6*D8)
See formula bar
3-53
Process Capability With OM Tools
3-54

All rights reserved. Reproduction or translation of this
work beyond that permitted in section 117 of the 1976
United States Copyright Act without express permission
of the copyright owner is unlawful. Request for further
information should be addressed to the Permission
Department, John Wiley & Sons, Inc. The purchaser
may make back-up copies for his/her own use only and
not for distribution or resale. The Publisher assumes no
responsibility for errors, omissions, or damages caused
by the use of these programs or from the use of the
information herein.
3-55

Ch03 SPC and Process Capability

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Ch03 SPC and Process Capability

Încărcat de

Drepturi de autor:

Formate disponibile

Chapter 3

Process Capability and

Basics of Statistical Process Control

Copyright 2011 John Wiley & Sons, Inc.

Statistical Process Control (SPC)

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

SPC in Quality Management

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

SPC Applied to Services

Copyright 2011 John Wiley & Sons, Inc.

SPC Applied to Services

Copyright 2011 John Wiley & Sons, Inc.

SPC Applied to Services

Copyright 2011 John Wiley & Sons, Inc.

Where to Use Control Charts

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Process Control Chart

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Control Charts for Attributes

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

20 samples of 100 pairs of jeans

Copyright 2011 John Wiley & Sons, Inc.

= 200 / 20(100) = 0.10

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Column values copied

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Control Charts for Variables

Mean chart ( x -Chart )

Copyright 2011 John Wiley & Sons, Inc.

x-bar Chart: Known

Copyright 2011 John Wiley & Sons, Inc.

x-bar Chart Example: Known

x-bar Chart Example: Known

Copyright 2011 John Wiley & Sons, Inc.

LCL = x=- z x= 5.01 - 3(.08 / 10)

x-bar Chart Example: Unknown

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Factor for X-chart

Factors for R-chart

x-bar Chart Example: Unknown

Copyright 2011 John Wiley & Sons, Inc.

x-bar Chart Example: Unknown

LCL = x - A2R = 5.01 - (0.58)(0.115) = 4.94

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

X-bar and R charts Excel & OM Tools

Copyright 2011 John Wiley & Sons, Inc.

Using x- bar and R-Charts

Copyright 2011 John Wiley & Sons, Inc.

Control Chart Patterns